Mitsubishi 380. Manual - part 978

 

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Mitsubishi 380. Manual - part 978

 

 

AK201661

MD998812

MD998813
MD998821

MD998364

AD

Synchronizer

hub

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-25

4. Using special tools, press install the 5th speed-reverse 

synchronizer hub with the press.

• Installer cap (MD998812)

• Installer-100 (MD998813)

• Installer adapter (MD998821)

• Camshaft oil seal installer (MD998364)

5. Make sure that the synchronizer ring on the 5th speed gear 

side can rotate freely.

.

>>N<< SYNCHRONIZER SLEEVE INSTALLATION

AK400081

Installation

direction

(5th speed side)

Identification

groove

AB

1. Check that the synchronizer sleeve is in the correct direction 

for installation, and install it on the 5th speed-reverse 
synchronizer hub.

AKX00928AD

Teeth with

raised tips

Deep grooves 

between the teeth

2. Install the synchronizer sleeve so that the areas with teeth 

that have raised tips (three areas total) are aligned with the 
areas on the synchronizer hub that have deep grooves 
between the teeth (three areas total).

.

>>O<< REVERSE GEAR BEARING SLEEVE INSTALLATION

AK201662AD

MD998364

MD998812
MD998820
Reverse

gear sleeve

Reverse

gear

1. Make sure the synchronizer ring, reverse gear and needle 

roller bearing have been correctly installed.

2. Using special tools, press fit the reverse gear sleeve. Make 

sure that the reverse gear and the synchronizer ring can 
rotate freely during the pressing process.

• Installer cap (MD998812)

• Installer adapter (MD998820)

• Camshaft oil seal installer (MD998364)

.

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-26

>>P<< TAPER ROLLER BEARING INSTALLATION

AK201663

MD998812
MD998819

MD998364

AD

Taper roller

bearing

Using special tools, press install the taper roller bearing.

• Installer cap (MD998812)

• Installer adapter (MD998819)

• Camshaft oil seal installer (MD998364)

.

>>Q<< SNAP RING INSTALLATION

AKX00934

Standard value

Snap ring

Taper roller

bearing

AD

1. Install the thickest snap ring that can be fitted in the groove 

of output shaft.

2. Make sure that the rear bearing end play meets the standard 

value.

Standard value: 0 

− 0.09 mm

INSPECTION

M1222002300227

.

OUTPUT SHAFT

AK204310AB

1. Check the splines for damage and wear.

2. Check that the helical gear teeth surfaces are not damaged 

or worn.

.

NEEDLE ROLLER BEARING
1. Combine the needle roller bearing with the bearing sleeve 

and gear, and check that it rotates smoothly without noise or 
play.

2. Check the needle roller bearing cage for deformation.

.

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-27

SYNCHRONIZER RING <FOR 5TH SPEED>

AK204298AB

1. Check if the clutch gear teeth are damaged.

2. Check internal surface for damage, wear and broken 

threads.

AK204307

A

Gear

Synchronize

ring

AB

3. Force the synchronizer ring toward the clutch gear and 

check clearance "A." If "A" is less than the limit, replace the 
synchronizer ring.

Minimum limit: 0.5 mm

.

OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER 
RING/SYNCHRONIZER CONE <FOR REVERSE>

AK204309AB

CAUTION

When replacing, replace the outer ring, inner ring and cone 
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces 

are not damaged or broken.

AK204259

Gear

A

Outer ring

Cone

Inner ring

AB

2. Install the outer ring, inner ring and cone, force them toward 

the gear, and check clearance "A." If "A" is less than the 
limit, replace them as a set.

Minimum limit: 0.5 mm

.

OUTPUT SHAFT

MANUAL TRANSMISSION OVERHAUL

22B-28

OUTER SYNCHRONIZER RING/INNER SYNCHRONIZER 
RING/SYNCHRONIZER CONE <FOR 1ST SPEED AND 2ND 
SPEED>

AK502785AB

CAUTION

When replacing, replace the outer ring, inner ring and cone 
as a set.
1. Check that the clutch gear tooth surfaces and cone surfaces 

are not damaged or broken.

AK203130AD

A

Outer ring

Inner ring

Cone

Gear

2. Install the outer ring, inner ring and cone, force them toward 

the gear, and check clearance "A." If "A" is less than the 
limit, replace them as a set.

Minimum limit: 0.5 mm

.

SYNCHRONIZER SLEEVE AND HUB

AK201697AD

Sleeve

Hub

1. Combine the synchronizer sleeve and hub, and check that 

they slide smoothly.

2. Check that the sleeve is free from damage at its inside 

splines ends.

.

SYNCHRONIZER SPRING

AKX00943

Check that the spring is not sagging, deformed or broken.

.

 

 

 

 

 

 

 

Content   ..  976  977  978  979   ..